FICHTNER SOLAR GmbH a company of the Fichtner group

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1 FICHTNER SOLAR mbh ISCC Kuraymat Integrated Solar Combined Cycle Power Plant in Egypt Paper FA4-S7 presented at 13th International Symposium on Concentrating Solar Power and Chemical Energy Technologies, SolarPaces, June 2-23, 6, Seville, Spain eorg Brakmann (Presenter) Fichtner Solar mbh, Sarweystr. 3, D-7191 Stuttgart, ermany, Tel.: , Khaled Fekry, New and Renewable Energy Authority (NREA), Egypt Ayman M. Fayek, New and Renewable Energy Authority (NREA), Egypt Abstract The New and Renewable Energy Authority (NREA) of Egypt intends to implement an Integrated Solar Combined Cycle Power Plant, ISCC Kuraymat, to be located about 95 km south of Cairo, on the eastern side of the river Nile, at a northern latitude of and an eastern longitude of The complete ISCC Project shall be implemented in three (3) contract lots: One (1) Contract Lot for Solar Island as EPC cum O&M contract for engineering, procurement, construction, testing, commissioning and five (5) years operation and maintenance; (Two contracts will be used for this Lot (Solar Island), one for EPC and one for the O&M part of the Lot.) The Solar Island shall consist of a parabolic trough solar field capable to generate about 11 MW (thermal) of solar heat at a temperature of 393 C, the related I&C and control room and the heat transfer fluid (HTF) system up to the HTF inlet and outlet flanges of the Solar Heat Exchanger(s). The Contractor for Solar Island shall guarantee the supply of solar heat to the Solar Heat Exchanger(s) as a function of normal direct solar irradiation (DNI) and of solar position. One (1) Contract for Combined Cycle Island as EPC contract for engineering, procurement, construction, testing and commissioning and extended two (2) year warranty period. The Combined Cycle Island shall consist of one (1) or two (2) gas turbine(s) with ISO rating of about 8 MWe (total), one (1) or two (2) heat recovery steam generator(s) (HRS), one (1) steam turbine of about 7 MWe, solar heat exchanger(s) capable to absorb about 11 MW (thermal) of solar heat plus all associated balance of plant equipment. The Contractor(s) for Combined Cycle Island shall guarantee the supply of electricity and the heat rate as a function of ambient temperature and as a function of solar heat supply from the Solar Island. One (1) Contract for Combined Cycle Island as O&M contract for five (5) year operation and maintenance. SolarPaces-Brakmann-Kuraymat-27Apr6.doc 1

2 FICHTNER SOLAR mbh Concept of the ISCC In a conventional combined cycle power plant the hot exhaust gases of the gas turbine(s) are used in the heat recovery steam generator (HRS) to produce steam which can be used in the steam turbine. In an ISCC (integrated solar combined cycle power plant) additional steam is used by a parabolic trough solar field. Thus during day time the electricity production is increased. The scope split (Figure 1) between the Solar Island and the Combined Cycle Island shall be the HTF inlet and outlet flanges of the Solar Heat Exchanger. The Solar Heat Exchanger shall be part of the Combined Cycle Island. 395 C Stack Exhaust C Steam 54 C, bar Storage (optional) Solar HX HRS Steam turbine ~ Cooling Tower Air and vapour Air Air Condenser Parabolic Trough Field 295 C C as turbine(s) ~ Electricity to the grid Solar Island Combined Cycle Island Figure 1 Scope Split and eneral Concept of an ISCC SolarPaces-Brakmann-Kuraymat-27Apr6.doc 2

3 FICHTNER SOLAR mbh Technical Design Data Detailed thermodynamic evaluations had been made by Fichtner Solar mbh during the conceptual design phase. However the bidders shall not be biased towards a certain gas turbine type, therefore the base line design data (Table 1) have been neutralized and are for information only. The Bidders are requested to provide their own design, in order to best fit the bid evaluation criteria. Neutralised Summary Technical Parameters of Baseline Design ISCC Solar field size m2 225 Capacity of gas turbine(s) (at ISO) MWe 8 Capacity of steam turbine (2 C, design solar heat) solar MWe 7 no solar MWe 38 ross capacity of plant (2 C, design solar heat) MWe 15 Net capacity (2 C, design solar heat) MWe 146 Net electric energy Wh/a 98 Energy of solar heat at baseline DNI Wh/a 225 Exergetic solar generation Wh/a 64,5 Table 1 Neutralized Summary Technical Parameters of Baseline ISCC Design SolarPaces-Brakmann-Kuraymat-27Apr6.doc 3

4 FICHTNER SOLAR mbh Site Location The site (Figure 2 and Figure 3) is located at the northern latitude of and the eastern longitude of It is some 95 km south of Cairo and about 2.5 km from the eastern shore of the Nile. Kuraymat Lat.: North Long.: East 25 km Figure 2 eographic location of the site Figure 3 Satellite view of the site SolarPaces-Brakmann-Kuraymat-27Apr6.doc 4

5 FICHTNER SOLAR mbh Plant Layout The area of ISCC Kuraymat consists of solar field areas, power block area, BoP area (Balance of Plant incl. non-plant buildings) and an area for a future test centre. A general plot plan of ISCC Kuraymat is shown in Figure 4. 5 kv transmission line Existing gas pipeline as station Water supply and discharge to Nile 5 m BoP area Switch yard Power block, EL 6 m N-W field, El 58 m 16 loops N-E field, EL 62 m 16 loops (+1) 678 m Test area Area for non plant buildings S-W field, EL 58 m 19 loops HTF header pipe S-E field, EL 58 m 18 loops (+1) 125 m 35 m 1346 m 3 m Figure 4 eneral Plot Plan and Location of ISCC Kuraymat SolarPaces-Brakmann-Kuraymat-27Apr6.doc 5

6 FICHTNER SOLAR mbh Solar Meteo Data The design basis DNI (Direct Normal Irradiation) for Kuraymat is kwh/m 2 /a. The annual distributions of DNI are shown in the following Figure 5. Solar Irradiations are shown in Figure 6 for a typical 21 December and 21 June. In December there is a large difference between DNI and DII (Direct Incident Irradiation); this is due to the lower solar elevation during winter months. The production of solar heat depends basically on the DII. The design ambient temperature varies between 2 C and 42 C, with an average of 21.6 C. The distribution of ambient temperature is shown in Figure 7. Distribution of DNI Distribution of DNI Distribution of DNI DNI (kwh/m2/d) DNI (W/m2) hours / a 2 1 Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec Month Hours during which DNI> values (h/a) DNI (W/m2) Figure 5 Distribution of DNI Solar Irradiation Solar Irradiation Dec DNI 7 DNI Irradiation (W/m2) 5 3 Incident Irradiation Irradiation (W/m2) 5 3 Incident Irradiation Figure 6 Solar Irradiation (DNI and DII) on typical 21 December and 21 June Design Air Temperatures Design Air Temperature Distribution (by Months) 1: Ambient Temperature ( C) Time (hour) Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec Ambient Temperature ( C) Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec Month 2: 3: 4: 5: 6: 7: 8: 9: 1: 11: 12: 13: 14: 15: 16: 17: 18: 19: 2: 21: 22: 23: 24: Figure 7 Ambient air temperature SolarPaces-Brakmann-Kuraymat-27Apr6.doc 6

7 FICHTNER SOLAR mbh Solar Heat and eneration of Electricity The distribution of solar heat being produced by the Solar Island and the correlation with ambient temperature is shown in Figure 8. Solar Heat Distribution Correlation solar heat and ambient temperature Solar Heat (MJ/s) h/a h/a Solar Heat (MJ/s) for 5 C for 2 C for 35 C for all C Figure 8 Distribution of Solar Heat and correlation with ambient temperature There is a higher frequency of occurrence of solar heat in the upper ranges when the ambient air temperature is higher. On the other hand higher ambient temperature causes a decrease in gas turbine power and in exhaust heat to the HRS (heat recovery steam generator). Thus the steam turbine can accommodate a larger amount of solar heat whenever the ambient air temperature is high. Nevertheless on high solar irradiation days the heat from the HRS (while the gas turbine is on full power) plus the solar heat can be larger than what can be accommodated by the steam turbine. For such cases there are three solutions: Increasing the size of the steam turbine The steam turbine size can be increased. A larger design of a steam turbine would result in higher cost and larger part load losses of the steam turbine during most of the year, whenever the solar heat is not close to its maximum. Throttling of the gas turbine During the peaking of solar irradiation the gas turbine can be throttled, resulting in less exhaust heat to the HRS; thereby the steam turbine can use all of the solar heat. This results in somewhat reduced output, but a better overall efficiency and hence a better use of the fossil fuel. Dumping of excess solar heat If a larger generation is desired during peaking of solar irradiation, then it is possible not to apply the throttling of the gas turbine, but to dump the excess solar heat by defocusing some collectors. This allows operating both the gas turbine and the steam turbine at full load. The power is maximised at the expense of efficiency. SolarPaces-Brakmann-Kuraymat-27Apr6.doc 7

8 FICHTNER SOLAR mbh Figure 9 and Figure 1 show respectively the Solar Heat and the Electricity eneration. On 21 December the direct incident irradiation and the ambient temperature are low. This results in less solar heat (see Figure 9a), but in more fossil generation (see Figure 1a). There is sufficient capacity in the steam turbine to absorb the entire solar heat. On 21 June the direct incident irradiation and the ambient temperature are high. This results in more solar heat, but in less fossil generation. Figure 1b shows the case when the gas turbine is throttled and most of the solar heat is used in the steam turbine. In Figure 1c the gas turbine is not throttled and consequently a larger quantity of the solar heat must be dumped. 12 Solar Heat 12 Solar Heat Solar Heat Solar Heat (MW-th) Dec dumping to storage direct used from storage Solar Heat (MW-th) dumping to storage direct used from storage Solar Heat (MW-th) dumping to storage direct used from storage (a) on 21 December (b) when throttling T (c) when dumping excess heat Figure 9 Solar Heat 16 Electricity eneration 16 Electricity eneration 16 Electricity eneration MWe Dec Solar gain Solar loss Solar gain / T throttling fossil production MWe Solar gain Solar loss MWe Solar gain Solar loss Solar gain / T throttling fossil production 2 2 Solar gain / T throttling fossil production (a) on 21 December (b) when throttling T (c) when dumping excess heat Figure 1 Electricity generation enerally in an ISCC, the steam turbine is sized larger than in a corresponding standard combined cycle power plant (with the same gas turbine). Therefore, whenever an ISCC operates without solar heat input (e.g. at night), the steam turbine will operate at part load and consequently at a lower efficiency, this is denominated as Solar loss in Figure 1. The evaluation criteria in the Bid Document for the Combined Cycle Island Contractor have been established so that an overall optimisation will be obtained, considering the sizing of the steam turbine in relation to the size of the Solar Island and the integration of solar heat into the Combined Cycle Island. SolarPaces-Brakmann-Kuraymat-27Apr6.doc 8

FICHTNER SOLAR GmbH a company of the Fichtner group

FICHTNER SOLAR GmbH a company of the Fichtner group Integrated Solar Combined Cycle Power Plants in Egypt and Morocco Georg Brakmann, Managing Director of Fichtner Solar GmbH, Sarweystr. 3, D-7191 Stuttgart, Germany, Tel.: +49 711 8995 535, email: brakmann@fichtnersolar.com

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